Dispensing carton for web material and blanks for making same



Nov. 11. 1969 J. c. BRANYON ET AL 3,477,624

DISPENSING CARTON FOR WEB MATERIAL AND BLANKS FOR MAKING SAME Filed April 17, 1967 5 Sheets-Sheet l FIG-l Nov. 11. 1969 J. c. BRANYON ET AL 3,477,624

DISPENSING CARTON FOR WEB MATERIAL AND BLANKS FOR MAKING SAME v Filed April 17, 1967 5 Sheets-Sheet v2 Nov. 11. 1969 J c BRANYON ET AL 3,477,624

DISPENSING CARTON FOR WEB MATERIAL AND BLANKS FOR MAKING SAME 5 Sheets-Sheet 5 Filed April 17, 1967 Nov. 11. 1969 J c BRANYON ET AL 3,477,624

DISPENSING CARTON FOR WEB MATERIAL AND BLANKS FOR MAKING SAME Filed April 17, 1967 5 Sheets-Sheet 4 a l F Nov. 11. 1969 J. c. BRANYON ET AL 7 DISPENSING CARTON FOR WEB MATERIAL AND BLANKS FOR MAKING SAME Filed April 17, 1967 5 Sheets-Sheet L5 United States Patent 3,477,624 DISPENSING CARTON FOR WEB MATERIAL AND BLANKS FOR MAKING SAME James Curtis Branyon and Allen L. Harshbarger, Louisville, and Maxie Martin, Pleasure Ridge Park, Ky., assignors to Reynolds Metals Company, Richmond, Va., a corporation of Delaware Filed Apr. 17, 1967, Ser. No. 635,295 Int. Cl. B262 3/02; B65d 5/72; B65h 75/32 US. Cl. 225-43 19 Claims ABSTRACT OF THE DISCLQSURE This invention pertains to an improved dispensing carton for web material, such as a web of metal foil, or the like, particularly adaptable to be used by commercial food packers and to blanks for making such dispensing carton. The improved dispensing carton of this invention has an elongated horizontally positioned rectan gualr slot located along the center portion of front wall means thereof adapted for pulling such web material therethrough. An extension flap is provided in its top wall means and such extension flap has cutting means provided in its terminal edge. The extension flap is adapted to be folded upon itself and the folded configuration is tucked behind the front wall means of such dispensing carton to position the cutting means above the top edge of the front wall means. Web material is easily pulled through the rectangular slot and cut to the desired length by pulling across the cutting means.

This invention pertains to container means and more particularly to an improved dispensing carton for web material and to blanks for making same.

Sheet materials such as coated paper, polyvinylchloride, metallic foil, and the like, are generally sold in roll form in a suitable dispenser. Competition is very keen in marketing of such sheet materials and quite often the provision of a dispensing carton which can be used efiiciently and which can be constructed with maximum economy so as not to increase the overall cost of the final product will help market the particular sheet material being sold. Presently known dispensers cannot be used with maximum efficiency and are comparatively expensive to produce.

Accordingly, it is a feature of this invention to provide an improved dispenser or dispensing carton for sheet material provided in roll form which enables such sheet material to be dispensed from such dispensing carton in an efiicient manner.

Another feature of this invention is to provide a dispensing carton of the character mentioned which is comparatively inexpensive to produce and which may be used to dispense web materials of all types.

Another feature of this invention is to provide an improved dispensing carton for dispensing web materials having integral means in its end walls for supporting mandrel means used to support such web materials for rotation.

Another feature of this invention is to provide an imice proved dispensing carton for dispensing web materials having horizontally arranged rectangular slot means provided in the central portion of front wall means comprising such carton enabling the terminal free end portion of web material carried within such dispensing carton to be easily pulled through such slot means.

Another feature of this invention is to provide an improved dispensing carton of the character mentioned in which such elongated horizontally arranged rectangular slot means is defined by a substantially rectangular flap hinged along its bottom edge by score means provided in such front wall means, whereby upon folding such rectangular flap means outwardly and pulling the terminal end portion of web material through such slot means a portion of such web material hangs freely so that it may be easily grasped by hand.

Another feature of this invention is to provide an improved dispensing carton of the character mentioned having top wall means foldably connected to rear wall means thereof and having integral extension flap means extending beyond front edge means of such top wall means and wherein score means is provided in such extension flap means enabling such extension flap means to be folded upon itself and tucked behind front wall means to position cutting means fixed to the terminal end of such extension flap means immediately above the top edge of the front wall means and thus enable efficient cutting of desired lengths of web material unrolled from within such dispensing carton.

Another feature of this invention is to provide an improved dispensing carton for web material which is adapted to be used in a high volume production packaging or wrapping operation wherein the arrangement of horizontal rectangular slot means and flap means in front wall means thereof and the positioning of integral cutting means are such that such front Wall means may be arranged facing away from an operator and wherein such operator simply reaches over the dispensing carton to easily graps an end portion of web material supported on such flap means and upon pulling a desired length of web material through such slot means the natural motion is to pull such length of web material toward the operator and across the cutting means and such natural motion is continued to place the severed section of web material onto suitable surface means adjacent the operator to enable wrapping of a food product, or the like, using such severed section of sheet material.

Another feature of this invention is to provide an improved dispensing carton of the character mentioned in which the horizontally arranged rectangular slot means provided in such front wall means is constructed and arranged so as not to materially weaken such front wall means and hence the entire dispensing carton.

Another feature of this invention is to provide an improved dispensing carton for dispensing web material such as metal foil, or the like, having uniquely constructed and arranged cutting means which provides efiicient cutting over extended use.

Another feature of this invention is to provide an improved high strength dispensing carton for web materials which may be made from a single piece blank of foldable 3 material and which does not require separate fastening means to hold such carton together.

Another feature of this invention is to provide an improved dispensing carton for web materials which does not require separate reinforcing means to hold such carton together during the unrolling and cutting of such web materials to desired lengths.

Therefore, it is an object of this invention to provide an improved dispensing carton for dispensing web material having one or more of the novel features of this invention as set forth above or hereinafter shown or described.

Another object of this invention is to provide improved blanks for making such improved dispensing carton or the like.

Other objects, uses, and advantages of this invention are apparent from a reading of this description, which proceeds with reference to the accompanying drawings forming a part thereof and wherein:

FIGURE 1 is a perspective view of one embodiment of an improved dispensing carton of this invention prior to opening thereof showing, by dotted lines, a roll of sheet material carried therein.

FIGURE 2 is the first of a series of perspective views used to show the unique construction of the dispensing carton of FIGURE 1 showing the top wall means or cover of the dispensing carton partially opened and particularly illustrating extension flap means extending beyond the front edge of such cover with cutting means provided at the terminal end of such extension flap means and further illustrating hinged flap means provided in front wall means of such carton to define a substantially rectangular opening or slot therein.

FIGURE 3 is the second perspective view of such series showing the free end portion of sheet material provided in roll form in such carton pulled through such rectangular slot and also illustrating the maner of folding the extension flap means upon itself.

FIGURE 4 is the third perspective view of such series showing the maner of placing or tucking the folded extension flap means behind the front wall means.

FIGURE 5 is the fourth perspective view of such series showing a desired length of such sheet material pulled upwardly through the horizontal rectangular slot and illustrating the position of the cutting means arranged immediately above the top edge of the front wall means.

FIGURE 6 is the fifth perspective view of such series illustrating the manner of severing such desired length of sheet material.

FIGURE 7 is a plan view of the blank used to make the improved dispensing carton of FIGURE 1 and also illustrating cutting means fastened to the terminal end of the extension flap means extending from the front edge of the top wall means.

FIGURES 8, 9, 10 and 11 illustrate successive steps of the preferred sequence used to fold the blank of FIGURE 7 to form the improved dispensing carton illustrated in FIGURE 1.

FIGURE 12 is a perspective view with parts broken away of the improved dispensing carton of FIGURE 1 showing the top wall means thereof opened and illustrating the manner of inserting a roll of sheet-like material within such dispensing carton.

FIGURE 13 is a sectional view on the line 1313 of FIGURE 1.

FIGURE 14 is a sectional vie won the line 14-14 of FIGURE 5'.

FIGURE 15 is a fragmentary perspective view illustrating another embodiment of the improved dispensing carton of this invention identical to the carton of FIGURE 1 with the exception that the cutting means is arranged on the inside surface of the extension flap means as determined with such extension flap means fully extended downwardly along the front wall means.

FIGURE 16 is an enlarged fragmentary perspective view illustrating the configuration of and manner of fastening the cutting blade defining such cutting means at the terminal end of the extension flap means of the carton of FIGURE 1.

While the various features of this invention are hereinafter illustrated and described as being particularly adaptable for providing dispensing cartons such as dispensing cartons for dispensing web material such as metal foil, or the like, adapted to be used in a food packaging operation, for example, it is to be understood that the various features of this invention can be utilized singly or in any combination thereof to provide dispensing cartons for dispensing all types of web materials and for other packaging operations, as desired.

Therefore, this invention is not to be limited to only the embodiments illustrated in the drawings because the drawings are merely utilized to illustrate one of the wide variety of uses of this invention.

In the exemplary embodiment of this invention illustrated in FIGURES 16 of the drawings an improved dispensing carton 20 is illustrated, as well as an improved blank, shown in FIGURE 7, for making such dispensing carton. Dispensing carton 20 is particularly adapted for dispensing web material or sheet means of material provided in roll form. In this example of the invention dispensing carton 20 is illustrated with a roll of metallic foil such as aluminum foil designated by the numeral 19 therewithin and adapted to be dispensed therefrom.

As seen particularly in FIGURE 1 of the drawings, dispensing carton 20 is in the shape of a parallelepiped and has a plurality of exterior walls shown as a front wall 21, a rear wall 22 arranged in parallel spaced apart relation from such front wall, a pair of parallel spaced apart end walls 23 and 24, and a bottom wall 25 and top wall 26.

Front wall 21 has opening means therein shown as a rectangular opening adapted for pulling a free end of the roll of metallic foil 19 carried within carton 20 therethrough. Opening 30 is defined by substantially U-shaped cut means shown as a U-shaped cut 32 provided along the central or mid-portion of front wall 21 and hinge means shown as a hinge line 33 extending between the terminal ends of the parallel legs of U-shaped cut 32 to thereby define a hinged flap 34 adapted to be folded outwardly about its hinge line 33, as seen in FIGURE 2 of the drawings.

Hinge line 33 is preferably a cut-score line extending horizontally along the front wall 21 in a rectilinear manner and preferably parallel to the top edge of front wall 21.

U-shaped cut 32 is arranged in front wall 21 in an inverted manner and so that its parallel leg portions are spaced inwardly of the side edge means or side edges 35 and 36 of front wall 21. This arrangement of the parallel legs of U-shaped cut 32 in spaced relation from the side edges 35 and 36 provides a strip of material at each end of rectangular opening 30 and each designated by the numeral 40. Each strip of material 40 in front wall 21 further assures that front wall 21 and hence carton 20 has optimum structural strength.

Flap 34 defining opening 30 is hinged outwardly to enable the free end of metal foil 19 to be pulled therethrough. The particular manner of forming cut-score line 33 is such that flap 34 generally assumes the upwardly inclined position or angle particularly shown in FIGURES 3 and 4 of the drawings. Upon pulling the terminal end portion of metallic foil 19 through rectangular slot 30, flap 34 supports metallic foil 19 at the same upwardly inclined angle with respect to the horizontal enabling the free end portion of such foil to be quickly and easily grasped by hand to unroll a desired amount, as shown in FIGURE 5, and then sever such desired amount by pulling across the cutting means provided on carton 20.

Top wall 26 of carton 20 is foldably connected to rear wall 22 along a score or fold line 44 and such top wall 26 has extension flap means shown as an extenslon flap 45 extending beyond a score line 46 defining front edge means or the front edge of top wall 26. With carton 20 closed as shown in FIGURE 1, extension flap 45 is normally positioned against the inside surface of front wall 21. Upon opening carton 20 to dispense metallic foil 19 therefrom, extension flap 45 is folded over upon itself in a manner as will be subsequently described.

Extension flap 45 is an integral flap extending from the edge of top wall 26 substantially coextensive therewith. Flap 45 has score means therein preferably formed as cut-score means 50 arranged parallel to score line 46 defining the front edge of top wall 26. Cut-score 50 essentially divides integral flap 45 into a pair of adjoining strip portions 51 and 52 comprising extension flap 45 and such extension flap is adapted to be folded upon itself so that its strip portions 51 and 52 adjoin each other as 'best seen in FIGURES 3 and 4 of the drawings.

Cutting means for cutting metallic foil 19 is provided and comprises a cutting blade 55 fixed to the terminal edge portion of extension flap 45 and specifically blade 55 is fixed to the terminal edge portion of strip portlon 52 defining the outer portion of extension flap 45. Blade 55 is fastened adjacent its inner edge to strip portion 52 and has an outer toothed cutting edge designated by the numeral 56 which extends beyond the terminal end of strip 52.

By folding extension flap 45 upon itself so that strip portions 51 and 52 are arranged with their flat surfaces against each other, the toothed edge 56 is positioned as shown in FIGURE 4; and, upon tucking the thus folded flap 45 behind front wall 21, toothed edge 56 is firmly held in cutting position immediately above the top edge of front Wall 21 so that each desired length of metal foil 19 may be pulled thereagainst and severed.

Means is provided along the opposite ends of extension flap 45 to assure that upon folding such flap upon itself it may be easily tucked behind front wall 21 while assuring such folded flap 45 is held firmly in position. Such means for holding folded flap 45 in position comprise arcuate tab portions or tabs each designated by the numeral 60 and provided at both ends of each strip portion 51 and 52.

Arcuate tab portions 60 in this exemplary embodiment of the invention are approximately semicircular in shape and such semicircular configuration makes it easier to tuck the folded flap 45 in position behind the top portion of front wall 21 especially because tabs 60 are adapted to be positioned against multiple thickness end wall 23 and 24 at each end of carton 20. Such multiple thickness end walls 23 and 24 cooperate with the double thickness of folded flap 45 to hold cutting blade 55 firmly in position over extended use without requiring additional anchors or special fasteners.

As seen particularly in FIGURES 12 and 13 of the drawings, the multiple thickness or layer end Walls 23 and 24 mentioned above are each of quadruple thickness. Each wall 23 and 24 has integral bearing surface means therein to enable supporting a mandrel or shaft 62 used to support the roll of metal foil 19 for rotation thereabout.

The integral bearing surface means provided in each wall 23 and 24 are defined by cooperating aligned openings provided in the inside three layers of each wall. Such aligned openings define a substantially cylindrical bearing or supporting surface 63 in end wall 23 and a similar substantially cylindrical supporting surface 64 in end wall 24.

Each quadruple layer or thickness end wall 23 and 24 in this example of the invention is preferably defined by extension flap means foldably connected to front wall 21 and rear wall 22. The manner of forming end walls 23 and 24 and their respective supporting surfaces 63 and 64 will be readily apparent from the description of the blank used to make carton 20 and the manner of assembling such blank and such description will be made subsequently.

As seen especially'in FIGURE 12 of the drawings, the roll of metal foil 19 is placed on shaft or mandrel 62 and one end of such shaft is inserted in position within cylindrical supporting surface 64 and the opposite end of shaft 62 is urged against end wall 23 to slightly bulge either one or both of end walls 23 and 24 outwardly. This slight bulging allows shaft 62 to snap in position in supports 63 and 64 at its opposite ends.

The roll of metal foil 19 is preferably supported on spool means such as a spool 65 provided to enable easy noncollapsing support of such metal foil. Spool 65 has a right circular cylindrical opening 66 extending therethrough having a diameter corresponding to the outside diameter of shaft 62 so as to enable easy rotation of the roll of metal foil 19 upon pulling its free terminal end, see FIGURE 14.

The inner layer of quadruple thickness end wall 23 has an elongated substantially rectangular cutout slot 71 therein. After placing one end of shaft 62 within surface 64, edge means 71A of slot 71 enables the opposite terminal end of such shaft to be lowered. into position in a guided manner with minimum bulging of end wall 23. Once such opposite end of shaft 62 reaches its lowermost position it slips or snaps into its associated cylindrical bearing surface 63 as illustrated in FIGURE 13 of the drawings.

With shaft 62 supported within its associated cylindrical bearing surfaces 63 and 64, provided integrally in end Walls 23 and 24 respectively, the free end of metallic foil 19 is pulled upwardly as illustrated by solid lines in FIGURE 14 to thereby rotate .roll 19 counterclockwise. Once the desired amount or length of metallic foil 19 is unrolled, the unrolled length is moved from the solid line position to the dotted line position of FIG- URE 14 and cut by toothed edge 56.

In this exemplary embodiment of the invention, the previously described cutting blade 55 is fastened to the terminal end portion of strip portion 52 comprising the extension flap 45 as illustrated in FIGURE 16 of the drawings. Blade 55 has a plurality of integral projection means or toothed riveting spike means, a representative few of which have been designated by the numeral 75, adjacent its iner edge 76. Toothed rivets 75 are adapted to be punched through strip portion 52 and riveted at the opposite side of such strip portion to hold blade 55 fixed in position.

Blade 55 has an arcuate configuration as seen at 77 between its toothed cutting edge 56 and its inner end or edge 76. The arcuate configuration enables the desired length of metallic foil which is unrolled from roll 19 to be urged against cutting edge 56 to provide a severing action without bending or deformation of blade 55 in any undesirable manner. Such arrangement assures that adequate cutting is provided over extended periods of usage even after dispensing numerous rolls using a single dispensing carton 20, if desired, yet without: abnormal wear to the toothed cutting edge 56.

Carton 20 may be formed in any suitable manner and made from any suitable foldable material. It is preferably formed from the blank 80, illustrated in FIGURE 7 of the drawings. Blank 80 is preferably made of cardboard, corrugated paperboard, or the like with adequate identification or dispensing instructions provided on its outside surface means. If desired, blank 80 may also have a side such as the exposed surface thereof laminated with metallic foil, such as aluminum-containing metallic foil, or the like, suitably colored, embossed, imprinted, or remaining plain where it is preferred to give the dispensing carton a decorative appearance.

Blank 80 is preferably made from a single piece of foldable material and although blade 55 is shown fastened 7 to blank 80 in FIGURE 7 this has been done for convenience and to highlight the simplicity with which blank 80 may be sequentially folded, as will be explained later, to form carton 20.

Blank '80 is suitably cut and scored and includes a series of parallel rectilinear score or fold lines 81, 82, 44, and 46 defining front wall 21 extending beyond score line 81, bottom wall 25 between score lines 81 and 82, rear wall 22 between score lines 82 and 44, and top wall 26 between score lines 44 and 46.

An extension flap designated generally by the numeral 45 extends beyond score line 46 in top wall 26 and extension flap 45 is divided into two substantially equal width sections by score line 50 extending thereacross parallel to score line 46. The equal width sections or portions are dsignated by the numerals 51 and 52 and each equal width portion 51 and 52 has an arcuate tab defining each of its opposite ends.

Front wall 21 has a U-shaped cut 32 therein and a cut-score line 33 extending between the terminal ends of the parallel leg portions of cut 32. The functions of cut-score line 33 and cut 32 were previously explained.

End walls 23 and 24 formed upon assembling carton 20 from blank are of quadruple thickness as previously mentioned and formed by extension flap means foldably connected to front wall 21 and rear wall 22. Such foldably connected extension flap means and the unique manner of folding and interlocking such flap means provides a dispensing carton which does not require separate fasteners, or the like, to keep it fastened together as a strong structural unit.

Front wall 21 has an extension flap extending beyond a score line 35 defining one end or side edge means of such front wall of the erected carton 20. Extension flap 85 defines outer surface means or the outer surface of end wall 23. The width of extension flap 85 is defined by a pair of parallel spaced apart score lines and 91 extending substantially in a rectilinear manner beyond one end of score line 81 and the top edge of top Wall 21 respectively.

A substantially rectangular extension flap 92 is provided at one side of flap 85 extending beyond score line 90. Flap 92 is defined by score line 90 at its base and a cut 92A defining one edge and arranged substantially in line with score line 35 and a cut 92B arranged in line with one end of score line 82 and defining the total extent or length of flap 92 beyond score line 90.

At the opposite side of extension flap 85, a short rectangular strip 94 is defined by a score line 95 which is arranged parallel to score line 91. Strip 94 defines top surface means for quadruple thickness end wall 23.

Another extension fiap 96 extends beyond score line 95 and is of substantially rectangular outline similar to fiap 85 and having practically the same size area. Flap 96 has a projecting tab 100 along its outer edge which is adapted to be used to hold end wall 23 in its vertical position as will be explained subsequently in more detail. Flap 96 defines the inside surface means of end Wall 23.

Cutouts are provided in both flaps 92 and 96 for reasons as will be presently explained. Flap 92 has a substantially rectangular cutout 101 therein which cooperates with tab 100 to hold end wall 23 in its erected vertical position. Flap 96 has a substantially rectangular cutuot slot designated by the numeral 71 and such cutout has a semicircular end 103 at one end thereof. The surface area defined by the semicircular end 103 comprises a portion of bearing surface 63.

Front wall 21 has a score line 36 defining its opposite end or side edge means and an extension flap 105 identical to extension flap 85 extending beyond score line 36. The width of extension flap 105 is defined by a pair of parallel spaced apart score lines 106 and 107 extending substantially in a rectilinear manner beyond the opposite end of score line 81 and the top edge of top Wall 21 respectively.

A substantially rectangular extension flap 110 is provided at one side of flap 105 extending beyond score line 106. Flap 110 is defined by score line 106 at its base and a cut 110A defining one edge thereof and arranged substantially in line with score line 36 and a cut 110B arranged in line with the opposite end of score line 82 and defining the length of flap 110 beyond score line 106.

In a similar manner as previously described in connection with flap 85, a short rectangular strip 111 is defined by a score line 112 which is arranged parallel to score line 107. Strip 111 defines top surface means for quadruple thickness end Wall 24 and adjoins flap 105.

Another extension flap 113 is provided extending beyond score line 112 and extension flap 113 is substantially the same width and area as extension flap 105. Extension flap 113 has a tab 114 comprising its terminal end portion and tab 114 is similar to tab 100.

Cutouts are also provided in both flaps 110 and 113 and such cutouts are similar in function to cutouts provided in flaps 92 and 96. Extension flap 110 has a rectangular cutout 115 wherein the surface adjoining such cutout is used to hold quadruple thickness end wall 24 firmly in position. Extension flap 113 has a circular cutout centrally arranged therein which cooperates with similar circular cutouts in other flap means defining end Wall 24 to define cylindrical bearing surface 64 in end wall 24 as will be subsequently described in detail.

Rear wall 22 has an extension flap 121 along one of its ends defined by a score line 122 arranged to define one end or side edge means of rear wall 22, a score line 123 arranged substantially in line with score line 44, and cut 92B. Extension flap 121 extends beyond rear Wall 22 and is generally coextensive in width therewith.

Extension flap 121 has a rectangular flap 124 extending therefrom and having its base defined by score line 123. The other three edges of flap 124 are defined by outer edge means of blank 80 along two edges and by a cut 127 extending generally in line with score line 122 to define the third edge.

Flaps 121 and 124 have circular cutouts 125 and 126 respectively in their central portions and such flaps are adapted to be folded against each other with cutouts 125 and 126 in aligned relation so that surface areas adjoining each cutout 125 and 126 cooperate to form a portion of bearing surface 63 provided in end wall 23.

Rear wall 22 has another extension flap 130 foldably fastened to its opposite end and extending beyond a score line 131 therein. The opposite side edges of flap 130 are defined by a score line 132 provided generally in line with score line 44 and by cut line 110B.

Flap 130 also has a rectangular flap 133 extending therefrom and having its base defined by score line 132. The other three edges of fiap 133 are defined by outer edge means of blank 80 along two sides and by a cut 128 extending generally in line with score line 131 to define the third edge.

Flaps 130 and 133 have circular cutouts 135 and 136 respectively in their central portions and such flaps are adapted to be folded against each other with cutouts 135 and 136 in aligned relation so that surface areas adjoining each cutout 135 and 136 cooperate to form a portion of cylindrical bearing surface 64 provided in end Wall 24.

Dispensing carton 20 is formed from blank 80 Without requiring any special separate fasteners of any kind; nevertheless, such dispensing carton retains high structural strength even after extended dispensing use.

The unique construction of blank 80 enables it to be folded together in a simple and efiicient manner to form carton 20 without requiring folding equipment or fixtures of any kind. Once erected, carton 20 is held locked together by the simple locking tabs 100 and 114 provided in flaps 96 and 113 respectively.

The shaft 62 supported within carton 20 does not require any additional supports even after extended dispensing use nor is there any tendency to pull carton 20 apart or weaken it in the course of normal dispensing use.

Although one-piece blanks have been previously proposed for forming dispensing cartons for sheet material provided in roll form, such previous blanks are usually expensive to produce and require additional supporting devices and fasteners to hold the assembled carton firmly together so that sheet material can be dispensed therefrom.

The simple manner in which the blank 80 is folded yet without requiring any tools will now be described and may be easily followed in FIGURES 8 through 11 of the drawings.

FIGURE 7 illustrates blank 80 with cutting blade 55 fastened firmly in position; however, it will be appreciated that blank 80 is suitably cut and scored from a suitable foldable material and such blade is then installed later. Use of a single piece blank makes it possible to easily store and ship such blanks, and in those instances where the blank is marketed with blade 55 installed, as shown, the assembly thereof to form carton is of utmost simplicity. The description will now proceed with blade 55 installed in position at the terminal end portion of extension flap 45.

As seen in FIGURE 8 blank 80 is initially placed on a flat surface and the front wall 21 is erected vertically while simultaneously moving extension flap 92 in adjoining relation on top of bottom wall with extension flap 85 folded at right angles thereto and extension flap 96 extending vertically above flap 85 so that flaps 96, 85 and 92 define an essentially L-shaped structure at one end of the partially assembled carton 20. In a similar manner flaps 110, 105, and 113 are folded to define another L-shaped structure positioned over the opposite end portion of bottom wall 25.

With the assembly thus erected, flap 124 is folded along score line 123 against flap 121 and flaps 121 and 124 are raised vertically normal to wall 22. In a similar manner, flap 133 is folded along score line 132 against flap 130 and flaps 130 and 133 are raised vertically at the opposite end of wall 22. The above folding sequence is particularly illustrated in FIGURE 9 of the drawings.

FIGURE 10 illustrates the next folding step in which wall 22 is raised so that it extends parallel to front wall 21 thereby moving overlapped flaps 121 and 124 against flap 85 at one end While moving overlapped flaps 130 and 133 against flap 105 at the opposite end of the assembly.

The next assembly step is illustrated in FIGURE 11 in which the vertically extended flaps 96 and 113 are then folded downwardly to define inside surface means of end walls 23 and 24 respectively.

Flap 96, upon being folded downwardly, sandwiches flaps 121 and 124 between it and outside wall 85 at one end of carton 20 and its tab 100 is then placed within slot 101 to lock end wall 23 and hence carton 20 securely at one end.

Similarly, flap 113 is folded downwardly to sandwich flaps 130 and 133 between it and outside wall 105 at the opposite end of carton 20 and its tab 114 engages slot 115 to hold end wall 24 and hence the opposite end of carton 20 firmly locked together.

The web of metallic foil 19 is then placed upon a suitable shaft 62 and supported in position within the assembled container and between end walls 23 and 24, see FIGURES 12 and 13. In the process of placing shaft 62 'in dispensing position, it can be seen that elongated slot Bearing surfaces 63 and 64 are formed by the thickness of the material used and such thickness is sufficient to provide an adequate bearing surface to support the opposite ends of the shaft 62. Also, the thickness of each wall 23 and 24 is used to hold tab portions 60 of overlapped, and hence of double thickness, extension flap 45 firmly in position to thereby securely hold blade 55 for cutting.

As will be readily apparent from FIGURES 10 and 11, strip portions '94 and 111 provided in end Walls 23 and 24 respectively define the top portions of such end walls and allow flaps 96 and 113 to be folded around the double thickness flaps sandwiched therebetween.

Another embodiment of this invention is illustrated in FIGURE 15 of the drawings. The embodiment of FIG- URE 15 is identical to the previously described embodiment and the blank used to make such embodiment is identical. The only difference is in the manner of attaching the blade 55 in position at the terminal end portion of extension flap 45.

In this latter embodiment blade 55 is arranged on the inside surface means or the inside surface of extension flap 45 as viewed with the entire flap 45 normally extended downward along front wall 21. The arrangement of blade 55 as illustrated in this latter embodiment provides an optional cutting arrangement. Upon folding sections 51 and 52 of the extension flap 45 of this latter embodiment in overlapping adjoining relation and tucking the folded flap in cutting position, such blade is arranged adjacent front wall 21.

Terms such as bottom, top, side, top Wall, front wall, upwardly, and the like have been utilized throughout this disclosure for ease of description and to define the position of various Walls as shown in the drawings, and it will be appreciated that such terms should not be considered as limiting the scope of this invention in any way.

Thus it is seen that an improved dispensing carton for web material has been provided by this invention which is of simple and economical construction and which does not require separate additional fastening means to hold the assembled carton together.

Further, this invention provides improved blanks for making such improved dispensing carton, or the like.

While the form of the invention now preferred has been disclosed as required by statute, other forms may be used, all coming within the scope of the claimed subject matter which follows.

What is claimed is:

1. A dispensing carton for dispensing web material to be carried therein comprising, parallel spaced apart front and rear wall means, opening means in said front wall means adapted for pulling a free end of said web material therethrough, top wall means for said carton foldably connected to said rear wall means and having integral extension flap means extending beyond front edge means of said top wall means and adapted to be folded along said front Wall means, cutting means for cutting said web material fixed along the terminal edge portion of said extension flap means, and score means in said extension flap means parallel to said front edge means of said top wall means enabling said extension flap means to be folded back upon itself and tucked behind said front wall means to position said cutting means above the top edge of said front wall means, whereby said web material is easily pulled through said opening means and cut in desired lengths by pulling across said cutting means.

2. The dispensing carton as set forth in claim 1 in which said opening means in said front wall means is defined by substantially U-shaped cut means in said front means and hinge means extending between the terminal ends of the parallel legs of said U-shaped cut means to define a hinged flap adapted to be folded about its hinge means to define horizontally extending slot means for pulling said web material thcrethrough.

3. The dispensing carton as set forth in claim 2 in which, the substantially parallel legs of said U-shaped cut means are of equal length and said U-shaped cut means is provided in the middle portion of said front wall means to define a substantially rectangular slot along said middle portion, the length of said extension flap means is less than the height of said front wall means, and the arrangement of said score means in said extension flap means is such that upon folding said extension flap means upon itself to position said cutting means in cutting position said rectangular slot means is kept open.

4. The dispensing carton as set forth in claim 3 further comprising a pair of multilayer end wall means each having integral support means therein for supporting mandrel means used to support said web material for rotation thereon.

5. The dispensing carton as set forth in claim 4 in which, each of said multilayer end wall means comprises a quadruple layer end wall, each quadruple layer end wall having its inner layers formed from extension flaps foldably connected to side edge means of said rear wall means and having its outer layers formed from extension flaps foldably connected to side edge means of said front wall means, and said integral support means being defined by cooperating surface means adjoining aligned opening means in selected inside layers of each end wall.

6. The dispensing carton as set forth in claim 2 in which said U-shaped cut means is arranged in said front wall means in an inverted manner and so that its parallel leg portions are spaced inwardly of side edge means of said front wall means, said arrangement of said U-shaped cut means defining said hinged flap hinged at its bottom edge while having said parallel leg portions sufficiently spaced from said side edge means of said front wall means to asure said front wall means has optimum structural strength.

'7. The dispensing carton as set forth in claim 6 in which said hinge means is defined by cut-score means in said front wall means and said slot means is a substantially rectangular slot means.

8. The dispensing carton as set forth in claim 7 in which said U-shaped cut means is provided in the middle portion of said front wall means to define a substantially rectangular slot along said middle portion, the length of said extension flap means is less than the height of said front wall means, and the arrangement of said score means in said extension flap means is such that upon folding said extenions flap means upon itself to position said cutting means in cutting position said rectangular slot means is kept open.

9. The dispensing carton as set forth in claim 7 in which said cutting means comprises an elongated thin blade having an outer toothed cutting edge and means adjacent its inner edge for fixing said blade to said extension flap means.

10. The dispensing carton as set forth in claim 9 in which said blade is fixed to outside surface means of said terminal edge portion of said extension flap means so that upon folding said extension flap means upon itself said blade is sandwiched between said folded portions of said extension flap means.

11. The dispensing carton as set forth in claim 9 in which said blade is fixed to inside surface means of said terminal edge portion of said extension flap means so that upon folding said extension flap means upon itself said blade is arranged outwardly of said folded portions of said extension flap means and immediately adjoining said front wall means.

12. The dispensing carton as set forth in claim 9 in which said outer toothed cutting edge of said blade and said inner edge of said blade extend in parallel spaced apart relation and the intermediate portion of said blade therebetween extends in an arcuate path to thereby provide added strentgh and rigidity to said thin blade in a direction generally transverse its outer cutting edge.

13. A blank being suitably cut and scored and adapted to be assembled to define a resulting dispensing carton for dispensing web material to be carried within said resulting carton, said blank comprising, spaced apart front and rear wall means adapted to define corresponding parallel front and rear wall means in said resulting carton, opening means in said front wall means adapted to receive a free end of said web material therethrough in said resulting carton, top wall means foldably connected to said rear wall means and adapted to define corresponding top wall means for said resulting carton, said top wall means having integral extension flap means extending beyond front edge means thereof and said extension flap means being adapted to be folded along the front wall means of said resulting carton, and score means in said extension flap means parallel to said front edge means of said top wall means enabling said extension flap means to be folded back upon itself and tucked behind said front wall means in said resulting carton to position the terminal edge portion of said extension flap means immediately above the top edge of said front wall means of said resulting carton, whereby cutting means is adapted to be fixed to the terminal edge portion of said extension flap means and upon assembling said resulting dispensing carton from said blank said web material is easily pulled through said opening means in the front wall means of said resulting carton and cut in desired lengths by pulling across said cutting means.

14. The blank as set forth in claim 13 made from a single piece of foldable material.

15. The blank as set forth in claim 14 in which said cutting means is fixed to said terminal edge portion of said extension flap means and provided as an integral part of said blank.

16. The blank as set forth in claim 14 in which said opening means in said front wall means is defined by substantially U-shaped cut means in Said front wall means and hinge means extending between the terminal ends of the parallel legs of said U-shaped cut means to define a hinged flap adapted to be folded about its hinge means to define slot means which in said resulting carton is arranged horizontally and is adapted to receive said web material therethrough.

17. The blank as set forth in claim 16 in which, said U-shaped cut means is arranged in said front wall means so that upon assembling said resulting dispensing carton from said blank said U-shaped cut means is arranged in said front wall means of said resulting carton in an inverted manner, said U-shaped cut means is dimensioned so that its parallel leg portions are spaced inwardly of side edge means of said front wall means, said hinge means comprises cut-score means, and said arrangement of said U-shaped cut means defines said hinged flap means hinged at its bottom edge in said resulting carton by said cut-score means while having its parallel leg portions sufiiciently spaced from said side edge means of said front wall means to assure said front wall means has optimum structural strength in the resulting dispensing carton.

18. The blank as set forth in claim 16 in which, the substantially parallel legs of said U-shaped cut means are of equal length and said U-shaped cut means is provided in the middle portion of said front wall means to define a substantially rectangular slot along said middle portion, the length of said extension flap means is less than the height of said front wall means, and the arrangement of said score means in said extension flap means is such that upon folding said extension flap means upon itself to position said cutting means in cutting position in said resulting carton said rectangular slot means is kept open.

19. The blank as set forth in claim 18 and further comprising, a first pair of extension flaps foldably connected to opposed side edge means of said rear wall means, a second pair of extension flaps foldably connected 13 to opposed side edge means of said front wall means, each extension fiap of said first pair being adapted to be overlapped and arranged substantially perpendicular to said rear wall in said resulting carton, each extension flap of said second pair being adapted to be wrapped around an associated overlapped first extension flap and arranged substantially perpendicular to said front wall to define an associated quadruple layer end wall in said resulting carton, and at least one cutout in each extensionz=flap defining an associated surface area, each of said cutouts being arranged in aligned relation with associated cutouts in said resulting carton to :define integral support means for supporting an associated end of mandrel means used to support said web material within said resulting carton.

References Cited UNITED STATES PATENTS FRANK T. YOST, Primary Examiner s. 01. X.R. 

